Haptic function leather component and method of making the same

ABSTRACT

A functional vehicle component and related methods include a functional leather assembly fixed over a vehicle component. The functional leather assembly includes a leather sheet, a flexible electronic circuit arranged on a first surface of the leather sheet that faces away from the vehicle component to thereby define an outermost surface of the leather sheet, and including a piezoelectric switch that can be actuated to make or break a conductive path in the circuit; and a pigmented coating arranged over the circuit. Upon actuation of the piezoelectric switch to make or break the conductive path in the circuit, the piezoelectric switch provides a haptic signal that indicates the actuation of the piezoelectric switch.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part application of U.S.application Ser. No. 15/635,803 filed Jun. 28, 2017; is acontinuation-in-part application of U.S. application Ser. No. 15/635,838filed Jun. 28, 2017; is a continuation-in-part application of U.S.application Ser. No. 15/635,862 filed Jun. 28, 2017; and claims priorityto U.S. Provisional Patent Application Ser. No. 62/667,178 filed May 4,2018; all of which are expressly incorporated herein by reference.

BACKGROUND

Interior vehicle components often include a surface layer of premiumnatural leather. The leather is wrapped around and secured to anunderlying structure. The leather is pliable, and thus conforms to thecontours of the underlying structure. In luxury vehicles, leather isgenerally applied as a top layer to components that may come in directcontact with occupants of the vehicle, such as interior panels, seats,and door linings. The main function of the topcoat of leather is foraesthetics and to provide a luxurious look to the interior of thevehicle. However, natural leather offers no functionality to the vehiclecomponents. Accordingly, there is a need for an improved top layer forvehicle components.

BRIEF DESCRIPTION

According to one aspect, a method of producing a functional leathercomponent includes providing a leather sheet, applying a flexibleelectronic circuit to an A-surface of the leather sheet, and arranging apigmented coating over the circuit.

According to another aspect, a method of producing a vehicle systemincludes applying a flexible electronic circuit to an A-surface of aleather sheet, electrically connecting a light source to the circuit,the light source configured to emit light when supplied with electricalpower, arranging a pigmented coating over the circuit and over the lightsource, fixing the leather sheet over a surface of a vehicle componentsuch that the A-surface of the leather sheet is facing away from thevehicle component, and connecting the circuit to a vehicle electroniccontrol unit and a vehicle power source. Optionally, the pigmentedcoating inhibits or prevents the circuit and the light source from beingvisible through the pigmented coating. Light emitted by the light sourceis visible through the pigmented coating.

According to another aspect, a functional vehicle component includes avehicle component, a leather sheet fixed over a surface of the vehiclecomponent, a flexible electronic circuit contacting an A-surface of theleather sheet and including a printed and cured conductive ink, and apigmented coating arranged over the electronic circuit.

According to another aspect, a vehicle system includes a vehicle powersystem and an electronic control unit electrically connected to thevehicle power system. The vehicle system also includes a functionalvehicle component including a vehicle component, a leather sheet fixedover a surface of the vehicle component, a flexible electronic circuitcontacting an A-surface of the leather sheet and including a printed andcured conductive ink, and a pigmented coating arranged over theelectronic circuit. The circuit is electrically connected to theelectronic control unit, which is configured to control operation of thefunctional vehicle component.

According to another aspect, a wireless charger for a vehicle includes avehicle power source; and a wireless charging apparatus including avehicle component, a leather sheet fixed over a surface of the vehiclecomponent, a flexible electronic circuit contacting an A-surface of theleather sheet and including a printed and cured conductive ink, and apigmented coating arranged over the circuit. The circuit is electricallyconnected to the power source and includes a wireless transmitterconfigured to generate an oscillating electromagnetic field whensupplied with power from the power source.

According to another aspect, a smart functional vehicle componentincludes a vehicle component, a leather sheet fixed over a surface ofthe vehicle component, a flexible electronic circuit contacting anA-surface of the leather sheet and including a printed and curedconductive ink, a light source that emits light when electrical power issupplied to the light source, the light source being electricallyconnected to the circuit, and a pigmented coating arranged over theelectronic circuit and over the light source.

According to another aspect, a vehicle system includes a vehicle powersystem; an electronic control unit electrically connected to the vehiclepower system; and a smart functional vehicle component including avehicle component, a leather sheet fixed over a surface of the vehiclecomponent, a flexible electronic circuit contacting an A-surface of theleather sheet including a printed and cured conductive ink that is inelectrical communication with the electronic control unit, a micro lightemitting diode that emits light when electrical power is supplied to themicro light emitting diode from the vehicle power system, the microlight emitting diode being electrically connected to the circuit, and apigmented coating arranged over the electronic circuit and over themicro light emitting diode. The electronic control unit is configured tocontrol operation of the functional vehicle component.

According to another aspect, a smart functional vehicle steering wheelincludes a vehicle steering wheel, a leather sheet fixed over a surfaceof the steering wheel, a flexible electronic circuit contacting anA-surface of the leather sheet and including a printed and curedconductive ink, and a pigmented coating arranged over the electroniccircuit. The circuit extends around the entire circumference of thesteering wheel and includes one or more pressure sensors arranged aroundthe entire circumference of the steering wheel.

According to another aspect, a method of producing a functional leathercomponent comprises providing a leather sheet; and applying to a firstside of the leather sheet, a flexible electronic circuit including apiezoelectric switch that can be actuated to make or break a conductivepath in the circuit. When the switch is actuated to make or break theconductive path in the circuit, the piezoelectric switch provides hapticfeedback that the piezoelectric switch has been actuated.

According to another aspect, a method of producing a functional leathercomponent comprises providing a leather sheet; applying to a first sideof the leather sheet, a flexible electronic circuit including apiezoelectric switch that can be actuated to make or break a conductivepath in the circuit; and arranging a pigmented coating over the circuit.When the switch is actuated to make or break the conductive path in thecircuit, the piezoelectric switch provides haptic feedback that thepiezoelectric switch has been actuated.

According to another aspect, a functional vehicle component comprises avehicle component covered by a functional leather assembly. Thefunctional leather assembly includes a leather sheet covering thevehicle component; and a flexible electronic circuit arranged on anoutermost surface of the leather sheet that faces away from the vehiclecomponent. The flexible electronic circuit includes a piezoelectricswitch that can be actuated to make or break a conductive path in thecircuit. Upon actuation of the piezoelectric switch to make or break theconductive path in the circuit, the piezoelectric switch provides ahaptic signal that indicates the actuation of the piezoelectric switch.

According to another aspect, a functional vehicle component comprises avehicle component covered by a functional leather assembly. Thefunctional leather assembly includes a leather sheet covering thevehicle component; a flexible electronic circuit arranged on anoutermost surface of the leather sheet that faces away from the vehiclecomponent; and a pigmented coating arranged over the circuit. Theflexible electronic circuit includes a piezoelectric switch that can beactuated to make or break a conductive path in the circuit. Uponactuation of the piezoelectric switch to make or break the conductivepath in the circuit, the piezoelectric switch provides a haptic signalthat indicates the actuation of the piezoelectric switch.

According to another aspect, a method of producing a functional vehiclecomponent, comprises applying to a first surface of a leather sheet, aflexible electronic circuit including a piezoelectric switch that isactuatable to make or break a conductive path in the circuit; arranginga pigmented coating over the first surface of the leather sheet and overthe flexible electronic circuit including the piezoelectric switch;fixing the leather sheet over a surface of a vehicle component such thatthe first surface of the leather sheet is facing away from the vehiclecomponent to thereby define an outermost surface of the leather sheet;and connecting the circuit to a vehicle electronic control unit and avehicle power source. Upon actuation of the piezoelectric switch to makeor break the conductive path in the circuit, the piezoelectric switchprovides a haptic signal that indicates the actuation of thepiezoelectric switch. Optionally, the pigmented coating inhibits orprevents the circuit including the piezoelectric switch from beingvisible through the pigmented coating.

According to another aspect, a method of producing a functional vehiclecomponent, comprises applying to a first surface of a leather sheet, aflexible electronic circuit including a piezoelectric switch that isactuatable to make or break a conductive path in the circuit; fixing theleather sheet over a surface of a vehicle component such that the firstsurface of the leather sheet is facing away from the vehicle componentto thereby define an outermost surface of the leather sheet; andconnecting the circuit to a vehicle electronic control unit and avehicle power source. Upon actuation of the piezoelectric switch to makeor break the conductive path in the circuit, the piezoelectric switchprovides a haptic signal that indicates the actuation of thepiezoelectric switch.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially exploded schematic view of a portion of a smartfunctional vehicle component in accordance with the present subjectmatter.

FIG. 2 is a perspective view of a use of a smart functional vehiclecomponent in accordance with the present subject matter.

FIG. 3 is a perspective view of another smart functional vehiclecomponent in accordance with the present subject matter.

FIG. 4 is a front view of another smart functional vehicle component inaccordance with the present subject matter.

FIG. 5 is a front view of another smart functional vehicle component inaccordance with the present subject matter.

FIG. 6 is a side view of another smart functional vehicle component inaccordance with the present subject matter.

DETAILED DESCRIPTION

In the era of smart phones and research toward autonomous vehicles,there is a need for creating smart functional interior vehiclecomponents having real-time bio feedback loops and dynamic surfaces.Smart functional vehicle components can be used to make a driver's andpassenger's driving experience more comfortable and enjoyable ascompared to non-functional vehicle components.

The present subject matter provides a smart functional layered assemblythat is flexible and therefore can be wrapped over various vehiclecomponents to make the vehicle components smart and functional. Thelayered assembly can be arranged on an interior or exterior of avehicle. The surface of the layered assembly presents a smooth and cleanfinish, and therefore has an uncluttered appearance despite having asmart functional capacity.

The present subject matter includes a substrate, for example a naturalsubstrate such as leather, textiles, etc., and includes making thesubstrate conductive, smart, and functional without cluttering theappearance of the substrate by including visible buttons, sensors, orother functional or smart elements on an A-surface of the substrate. Thepresent subject matter will provide a dynamic interior experience foroccupants of a vehicle, yet provide a functional vehicle component thathas an uncluttered appearance.

Referring now to the figures, wherein the showings are for purposes ofillustrating one or more embodiments only and not for purposes oflimiting the same, FIG. 1 depicts a smart functional vehicle component 2(also referred to herein as “functional vehicle component 2” including asmart functional layered assembly 4 (also referred to herein as a“layered assembly” or as a “functional leather assembly”) arranged on avehicle component 8.

The smart functional layered assembly 4 includes a leather sheet 10fixed over the surface 6 of the vehicle component 8, a flexibleelectronic circuit layer 12 (also referred to herein as “circuit layer12”) applied to an A-surface 14 of the leather sheet 10, and a pigmentedcoating 16 over the circuit layer 12. As used herein, “A-surface” refersto the outermost surface of the leather sheet 10 that is most visible(i.e. facing) to the vehicle occupants after the functional vehiclecomponent 2 including the leather sheet 10 is assembled and arrangedin/on a vehicle; while a B-surface, a C-surface, a D-surface, etc. areother surfaces of the leather sheet that are progressively less visiblethan the A-surface 14. On a functional vehicle component 2 in aninterior of a vehicle, the A-surface 14 of the leather sheet 10 isfacing the vehicle occupants and unless covered by another layer orfeature, may be visible to the occupants of the vehicle. The A-surface14 may be what is referred to in the leather industry as the grain side,the skin side, the top side, or the hair side of the leather sheet 10.The grain side, the skin side, the top side, or the hair side is theside of the leather sheet 10 opposite from what is referred to in theleather industry as the flesh side or back side of the leather sheet 10.The flesh side is the side of the leather sheet 10 that is connected tothe meat of the animal from which the leather sheet 10 is taken. Thefunctional layered assembly 4 optionally includes an anti-soilingcomponent layer 18. However, in an alternative embodiment, thefunctional layered assembly 4 may not include a separate and distinctanti-soiling component layer 18, and instead can include an anti-soilingcomponent as part of the pigmented coating 16.

The vehicle component 8 is not particularly limited by the presentsubject matter, and may include any interior vehicle component such asan interior panel, a door, a seat, a steering wheel, an arm rest, adashboard, a center console, a gear shifter or any other interiorcomponent that can be wrapped with leather. Optionally, the vehiclecomponent 8 can include an exterior vehicle component. The vehiclecomponent 8 is different from the smart functional vehicle component 2,in that the vehicle component 8 does not include the smart functionallayered assembly 4 applied over its surface 6. In one non-limitingembodiment, the vehicle component 8, before assembling with thefunctional layered assembly 4, does not include any smart or functionalelements or features such as sensors, processors, circuits, switches, orthe like. However, it will be understood that the vehicle component mayinclude smart or functional elements aside from those included on thesmart functional layered assembly 4.

The surface 6 of the vehicle component 8 may be smooth or textured, andflat or contoured. In one non-limiting example, the A-surface 6 of thevehicle component 8 is contoured. In any event, the functional layeredassembly 4 is fixed over the surface 6 of a vehicle component 8 in orderto make the vehicle component 8 smart and functional.

The leather sheet 10 may be fixed over the surface 6 of the vehiclecomponent 8 in order to enhance the aesthetics of the vehicle component.The leather sheet 10 may be naturally flexible, pliable, andstretchable, and therefore can be wrapped around or over the vehiclecomponent 8 and conforms to the contours of the surface 6 of the vehiclecomponent 8. Because the circuit layer 12 and circuits 20 are flexibleand are applied to the A-surface 14 of the leather sheet 10, the circuitlayer 12 and circuits 20 are also conformed to the contours of thesurface 6 of the vehicle component 8. The leather sheet 10 may be indirect contact with the surface 6 of the vehicle component 8, or mayhave one or more optional layers therebetween. Optionally, the leathersheet 10 may simply cover or be over the surface 6 of the vehiclecomponent 8.

The leather sheet 10 may be prepared in any number of ways including byregular tanning processes including soaking, sammying, shaving,fleshing/splitting, drying, staking, and milling of natural leather. Theleather sheet 10 may be replaced or supplemented with bonded leather,synthetic leather, other leather composite material, or other materialor layers as desired. The leather sheet 10 may be cut or formed to aparticular size or shape to correspond to the shape and size of thevehicle component 8 to which it will be wrapped. In accordance with thepresent subject matter, the leather sheet 10 may have a shape and sizethat is configured to wrap over a surface of an interior panel, a door,a seat, a steering wheel, a dashboard, a center console, or a gearshifter.

Either before or after fixing the leather sheet 10 over the surface 6 ofthe vehicle component 8, the various other layers (i.e. circuit layer12, pigmented coating 16, and optional anti-soiling component layer 18)of the functional layered assembly 4 may be applied to the leather sheet10. In one embodiment, the leather sheet 10 is fixed over the surface 6of the vehicle component 8 after the various other layers of thefunctional layered assembly 4 are applied to the leather sheet 10. Inanother embodiment, the leather sheet 10 is fixed over the surface 6 ofthe vehicle component 8 before the various other layers of thefunctional layered assembly 4 are applied to the leather sheet 10.

The leather sheet 10 may be flexible, and therefore in one non-limitingembodiment, may be fixed over the surface 6 of the vehicle component 8by stretching and wrapping the leather sheet 10 around the vehiclecomponent 8. The leather sheet 10 may be fixed, such as by adhesive orfasteners, to the surface 6 and/or other portion of the vehiclecomponent 8.

In one embodiment, the circuit layer 12, pigmented coating 16, andoptional anti-soiling component layer 18, even though they are appliedover the A-surface 14 of the leather sheet 10, still allow somecharacteristics (e.g. surface texture or grain, and softness) of theleather sheet 10 to be at least partially perceived by occupants of thevehicle, such as by touch or sight.

The circuit layer 12 is provided over the A-surface 14 of the leathersheet 10 in order to provide smart functional characteristics to theleather sheet 10. The circuit layer 12 consists of one or more flexibleelectronic circuits 20 (also referred to herein as “electronic circuits”or “circuits”), and is arranged on the A-surface 14 of the leather sheet10. Although the circuit layer 12 is depicted in FIG. 1 as being acontinuous layer, this is only for convenience in order to show thearrangement of the various layers of the smart functional vehiclecomponent 2, and it will be understood that the circuit layer 12 may ormay not comprise voids between conductive traces of the one or morecircuits 20, and therefore the circuit layer 12 may or may not be acontinuous layer as depicted.

In one embodiment, the circuit layer 12 contacts the A-surface 14 of theleather sheet 10. In another embodiment, the circuit layer 12 isarranged on a polymer film, which is then arranged over the A-surface 14of the leather sheet 10. The one or more circuits 20 of the circuitlayer 12 each include one or more flexible conductive traces 22 (alsoreferred to herein as “conductive traces”, “conductive paths” or“traces”). By “flexible”, it is meant a layer, circuit, trace or otherelement or material that is not rigid, brittle, or stiff, and insteadbends, stretches, changes shape, or otherwise yields to external forces,yet does not break or lose functionality when subject to such externalforces. When referring to a “flexible electronic circuit”, it is meantan electronic circuit 20 that does not break and retains itsconductivity even when bent, stretched, twisted or otherwise deformed toa strain of 10% to at least 20%.

In one embodiment, the circuit layer 12 includes only one electroniccircuit 20. In another embodiment, the circuit layer 12 includes morethan one electronic circuit 20, for example, two, three or moreelectronic circuits 20. When more than one circuit 20 is included in thecircuit layer 12, each individual circuit 20 may be configured toperform a different function than the other circuits 20, which may meanthat each circuit 20 is electrically isolated/separated from the othercircuits 20, or the circuits 20 can be independently operated, or eachcircuit 20 can function separately from the other circuits 20, or thecircuits 20 are electrically connected to different types of electronicelements 24.

The one or more circuits 20 (including one or more conductive traces 22)and the electronic elements 24 may each be formed using an electricallyconductive ink that includes a binder (e.g. polymer material such aspolyimide) and conductive particles, including for example, copper,silver, carbon, silver chloride, or other electrically conductiveparticles. The one or more circuits 20 each may be formed by applying,e.g. printing, a conductive ink directly on the A-surface of the leathersheet, followed by curing, drying, hardening, etc. of the conductiveink, to thereby form the conductive traces 22, circuits 20, andelectronic elements 24 of the circuit layer 12. In other words, theconductive traces 22, circuits 20, and electronic elements 24 may bedefined by or include a printed and cured conductive ink. Conductiveinks that are suitable to create the one or more circuits 20 andelectronic elements 24 are not particularly limited, and may include forexample, PE671, PE773, PE873, and PE971 Stretchable Conductors, PE410Ink-Jet Silver Conductor, 5021, 5025, 5028, and 5064HY Ag Conductors,ME601 and ME602 Stretchable Silver Conductors, PE827 and PE828 Ultra-LowTemperature Cure Silver Composit Conductors, Kapton™ KA801 PolyimideSilver Conductor, available from E. I. du Pont de Nemours and Company;and CI-1036, CI-4040, CI-2051, and CI-1062 Stretchable Conductive Inkavailable from Engineered Materials Systems, Inc. (EMS).

These conductive inks can be applied on the surface 14 of the leathersheet 10 by any method including pad-printing, flexography, rotogravure,spraying, dipping, syringe dispensing, stenciling, screen printing,aerosol jet printing, or inkjet printing for example in order to createan electronic circuit. The flexible electronic circuits 20 can be formedusing other materials or processes including etching, in-mold forming ofthe electronic circuits 20, selective photocuring, and circuit scribe,for example. In one illustrative embodiment, the one or more circuits 20are formed by screen printing a conductive ink on the surface 14 of theleather sheet 10.

The one or more circuits 20 can each include electronic elements 24 suchas power sources, capacitors, inductors, diodes, resistors,transformers, switches, sensors, loads, light sources, fuses, antennas,wireless transmitters, heaters, etc., each of which may be flexible.However, it will be understood that these or other electronic elementsmay be included in electrical communication with the circuits 20, butarranged elsewhere other than as part of the circuit layer 12. In onenon-limiting example, a light source 30 is included as an electronicelement 24 in the functional vehicle component 2. In anothernon-limiting example and as shown in FIGS. 1 and 2, a wirelesstransmitter 34 (e.g. an induction coil, or a capacitive plate) isincluded as an electronic element 24 in the functional vehicle component2. In a further non-limiting example, one or more sensors 38 areincluded in an electronic circuit of the circuit layer 12. In stillanother non-limiting example, a switch 40 is included in an electroniccircuit of the circuit layer 12.

The pigmented coating 16 may be arranged over the circuit layer 12 to atleast partially conceal or camouflage the circuit layer 12 including theelectronic elements 24. The pigmented coating 16 is not particularlylimited by the present subject matter, and may include a translucentlayer, film, or coating arranged over the flexible circuit layer 12. By“translucent” it is meant a material or layer that allows light to passtherethrough, but causes sufficient diffusion to prevent perception ofdistinct images through the material or layer. In an embodiment, thepigmented coating 16 is not included, or the pigmented coating 16 isclear (i.e. optically transparent) and/or the circuit layer 12 andelectronic components thereof are positioned on top of the pigmentedcoating 16. In a non-limiting example, the pigmented coating 16 producessufficient diffusion of light such that visibility through the pigmentedcoating 16 of the flexible electronic circuit 20 and all the electronicelements 24 of the circuit layer 12, except for light emitted by thelight source 30, is inhibited by the pigmented coating 16. In oneembodiment, the flexible electronic circuit 20 and all the electronicelements 24 of the circuit layer 12 are not visible through thepigmented coating 16. The light source 30 is also under the pigmentedcoating 16, and therefore visibility of the light source 30 through thepigmented coating is inhibited by the pigmented coating 16. In oneembodiment, the light source 30 is also not visible through thepigmented coating 16. However, the pigmented coating 16 is sufficientlytranslucent (rather than being opaque) such that light emitted by thelight source 30 is visible through the pigmented coating 16.Accordingly, the pigmented coating 16 at least in some measure concealsthe flexible circuit layer 12 (including the light source 30) from view,yet allows light emitted from the light source 30 to be transmittedtherethrough so that the emitted light is visible through the pigmentedcoating 16 and can be seen. Light emitted from the light source 30 thatis transmitted through the pigmented coating 16 may be seen for example,by a vehicle occupant, and can be used for vehicle illumination or asvisual indicators to convey information to a vehicle occupant.

The pigmented coating 16 may be polymer, textile, composite material,enamel, paper, glass, metal, ceramic, other material, and combinationsthereof. In one non-limiting example, the pigmented coating 16 comprisesa pigmented layer including for example a mixture of polymer and pigmentparticles. The polymer may be an acrylic urethane resin for example. Thepigmented coating 16 may be formed by applying the polymer/pigmentmixture as a liquid over the flexible circuit layer 12 and curing thepolymer to produce the pigmented coating 16 as a solid. The pigmentedcoating 16 may have a pigment loading and/or thickness sufficient toinhibit or prevent the circuit 20 and the electronic elements 24including the light source 30 from being visible through the pigmentedcoating 16. However, the pigmented coating 16 is sufficientlytranslucent, as opposed to being opaque, such that light emitted by thelight source 30 can be seen through the pigmented coating 16. In onenon-limiting embodiment, the pigmented coating 16 has a thickness from5-50 μm, 15-40 μm, or 20-30 μm.

The anti-soiling component layer 18 or an anti-soiling componentincluded in the pigmented coating 16, may present an exposed surface ofthe functional vehicle component 2, and these are optionally included toresist any type of dirt while maintaining all physical and aestheticalproperties of the underlying layers of the functional layered assembly4. The anti-soiling component layer 18 is not particularly limited bythe present subject matter, and may include an anti-soiling componentincluded as a distinct layer as depicted in FIG. 1. Alternatively, ananti-soiling component may be included as part of the pigmented coating16. In a non-limiting embodiment as depicted in FIG. 1, when included asa distinct layer in the functional layered assembly 4, the anti-soilingcomponent layer 18 is essentially transparent (and may be opticallytransparent) such that the anti-soiling component layer 18 does notsignificantly interfere with the transmission of light emitted by thelight source 30. In another embodiment, the anti-soiling component layer18 may be slightly pigmented such that it assists the pigmented coating16 in concealing the circuit layer 12 from view. In one non-limitingembodiment, the anti-soiling component layer 18 has a thickness from0.1-10 μm, 1-8 μm, or 4-6 μm.

The anti-soiling component included in an anti-soiling component layer18 or in the pigmented coating 16, is not particularly limited and maycomprise acrylic urethane resin, polyurethane resin, polyisocyanate,carbodiimide, fluorine-containing materials such as tetrafluoroethylene(TFE)-copolymers, silicone, etc.

Operation of the functional vehicle component 2, the electronic circuits20, and the associated electronic elements 24 may correspond to signalsor data derived from one or more electronic systems of a vehicle or maybe continuously activated during operation of the vehicle. The data orsignals may be accessed from, sensed by, generated by, or otherwiseacquired from or produced by one or more of the vehicle electronicsystems. Further, the functional vehicle component 2, the electroniccircuits 20, and the associated electronic elements 24 may providesignals or data to the one or more electronic systems of the vehicle.For example and as described in more detail herein, the functionalvehicle component 2 may include a sensor 38 and signals from the sensor38 may be communicated to the vehicle electronic systems, and may beused to operate other electronic elements 24 in the functional vehiclecomponent 2 or to operate a different functional vehicle component.

The vehicle electronic systems from which this data or these signals arederived or to which this data or these signals are communicated, are notparticularly limited and may include one or more vehicle electroniccontrol units (ECU's) associated with a vehicle engine, transmission,body, chassis, passive and active safety features, vehicle performance,driver assistance, interior and exterior environment, vehiclediagnostics, vehicle control, audio/visual entertainment, navigation,electrical systems, telematics, and combinations thereof. The vehicleelectronic systems can include a door control unit, engine control unit,electric power steering control unit, human-machine interface (HMI),powertrain control module, transmission control unit; seat control unit,speed control unit, telematics control unit, transmission control unit,brake control module (ABS or ESC), battery management system, centralcontrol module, central timing module, general electronic module, bodycontrol module, suspension control module, or combinations thereof.

In a non-limiting example, the one or more flexible electronic circuits20 are in communication with a vehicle electronic control unit (ECU) 26,which may control operation of the functional vehicle component 2, theelectronic circuits 20, and the associated electronic elements 24. TheECU 26 may be electrically connected to a vehicle power source 44 forpowering the ECU 26 or flexible electronic circuits 20. The functionalvehicle component 2, including the one or more circuits 20 of thecircuit layer 12, along with the various electronic elements 24, may beselectively operable based on a current condition or situation relatingto the vehicle or vehicle components, an occupant of the vehicle, or anenvironment of the vehicle including an immediate or a distantsurrounding environment of the vehicle, and combinations thereof.

A non-limiting example of the conditions of the vehicle that may be usedas a basis for such selective operation include historical, current, orprojected vehicle performance characteristics or diagnostic information,or the like. Conditions of the vehicle occupants that may be used as abasis for such selective operation can include a physical condition of adriver, such as the driver being drowsy or inattentive while driving, orthe proximity of an object (such as an occupant or an occupants hand) ora global position relative to the vehicle or to the functional vehiclecomponent 2. Conditions of the surrounding environment that may be usedas a basis for such selective operation can include proximity of anobject (such as another vehicle) to the vehicle, the current time,newsfeeds, amber alerts, nearby points of interest, or the like.

In another non-limiting example, the one or more circuits 20 are incommunication with a human machine interface (HMI) 28, which may controlfunctioning of the functional vehicle component 2, the electroniccircuits 20, and the associated electronic elements 24. Such arrangementcould allow a user to provide input through the HMI 28 to selectivelyactivate the circuits 20 and associated electronic elements 24. Suchuser input may be active (user initiated) or passive (sensed input froma user), and can include audible or tactile input. For example, thesystem may be configured to allow a user to audibly select operation ofthe functional vehicle component 2, the electronic circuits 20, and theassociated electronic elements 24.

As previously disclosed, a light source 30 may be included as anelectronic element 24 in the functional vehicle component 2. The lightsource 30 may comprise one or more separate and distinct light emitterelements 32. The light source 30 emits light when activated, and iselectrically connected to an electronic circuit 20 of the circuit layer12. The light source 30 may simply provide illumination by emittinglight, which may be used to provide illumination to the interior orexterior of the vehicle, and the light source 30 may emit light in oneor more colors and/or intensities. In a non-limiting example, the lightsource 30 may emit various colors and intensities of light to establisha particular “feel” or “mood” for occupants of the vehicle. For example,the light source 30 may be paired to certain functions of the vehicle orvehicle components, such that the light source 30 operates to emit lightat different intensities and/or colors depending on certaincircumstances such as during normal operation of the vehicle, duringoperation of a vehicle entertainment system, during dangerous operationof the vehicle, or other circumstances or situations as desired.

Alternatively, the light source 30 may be configured, such as byarrangement or operation, to emit light that provides visual indicatorsthat convey information to a vehicle occupant. In other words, the lightsource 30 may be arranged in such a way, or may emit light in such a waythat the light emitted by the light source 30 provides more than mereillumination, and instead additionally conveys information to a vehicleoccupant.

The visual indicators are not particularly limited by the presentdisclosure, and may provide information such as warnings, notices (e.g.the time), alerts, instructions, information relating to a currentcondition or situation relating to the vehicle or vehicle components, anoccupant of the vehicle, or an environment of the vehicle including animmediate surrounding environment of the vehicle, and combinationsthereof. The visual indicators may include one or more of directionalindicators such as turn-by-turn directions from a navigation system,blind spot warnings, a turn signal indicator, and combinations thereof.However, such indicators are not limited to any particular type orcombination. Other illustrative examples include maintenance indicatorsto display information such as fluid levels/amounts such as oil or gas(or the need to change one or more fluids such as oil), battery levelindicators to display characteristics of one or more batteries on thevehicle, vehicle characteristic indicators (e.g. the current speed ofthe vehicle), and indicators to display the distance to a desireddriving destination. In one illustrative embodiment, the light emittedby the light source 30 indicates a location of the one or moreelectronic circuits 20 or electronic elements 24 electrically connectedto the electronic circuits 20 of the circuit layer 12. In anotherillustrative embodiment, the light source 30 emits light that provides adirectional indicator to a driver of the vehicle, or a current time, ora current amount of fuel reserves for the vehicle.

The light source 30 may be activated to emit light when a certainassociated object is within a predetermined distance from the functionalvehicle component 2. In one embodiment, the light source 30 is activatedto emit light when a portable electronic device 42 is within apredetermined distance from the functional vehicle component 2. Inanother embodiment, the functional vehicle component 2 is incommunication with an HMI 28, which could allow a user to provide inputto activate the light source 30 by selecting a particular type ofinformation to be displayed by the light source 30. For example, thesystem may be configured to allow a user to audibly select which fluidlevel (such as gas, oil, windshield wiper) to indicate in real-time orto allow a user to audibly request how much time until a desireddestination is reached.

The visual indicators may correspond to signals or data derived from theelectronic systems of a vehicle or an HMI. In one embodiment, electronicsystem of the vehicle provide real-time signals or data that may bedisplayed by the light source 30. Communication between the functionalvehicle component 2 and the vehicle electronic system or HMI may beestablished through one or more intermediary systems or devices, andsuch communication may be performed, for example, by using acommunication link or connection such as with a wired connection, Wi-Ficonnection, Bluetooth connection, etc. Such communication connectionallows the data or signals from/to the vehicle electronic system or HMIto be communicated to activate the light source 30 to provide the visualindicators to a vehicle occupant that corresponds to such data orsignals.

The light source 30 is not limited in any way and can includeluminescent light sources (e.g. electroluminescent, photoluminescent,mechanoluminescent light sources), and incandescent light sources.Illustrative examples of light emitter element 32 include a lightemitting diode (LED), an organic light emitting diode (OLED), or aphotoluminescent or electroluminescent light source configured in a filmor sheet. In a non-limiting example, the one or more light emitterelements 32 comprises LED's having a light emitting area with a size of100 μm×100 μm (i.e. 100 μm diameter) or less, herein referred to microLED's. A micro LED is a light source that consists of an array of one ormore individual light emitters, wherein an array may have a diameter ofabout 2 μm-20 mm and the individual light emitters have typicaldiameters of about 2-20 μm. In one aspect, the one or more micro LED'sare arranged as part of an electronic circuit 20 of the circuit layer12.

As previously discussed, and as depicted in FIG. 2, the functionalvehicle component 2 may comprise a smart functional wireless charger 82including a wireless transmitter 34 (e.g. an induction coil, or acapacitive plate), which is included as an electronic element 24 in thefunctional vehicle component 2. The wireless transmitter 34, mayoptionally be formed by printing a conductive ink in a process asdescribed herein with respect to the flexible circuits 20, wherein theconductive ink is applied in the form of an induction coil or capacitiveplate. The wireless transmitter 34 may be configured to generate anoscillating electromagnetic field 36 when activated, which can betransmitted to a corresponding wireless receiver that is configured toreceive the oscillating electromagnetic field. The wireless transmitter34 and the generated oscillating electromagnetic field 36 may be used tocharge a portable electronic device 42 (e.g. a cell phone) that includesthe corresponding wireless receiver, which receives the oscillatingelectromagnetic field 36 and converts the oscillating electromagneticfield 36 back to DC or AC electric current that can be used by anelectrical load in the portable electronic device 42.

As is conventional, the wireless transmitter 34 may be able to transmitthe oscillating electromagnetic field 36 to the corresponding wirelessreceiver in the portable electronic device 42 only over a shortdistance, e.g. about 1-10 times the transmitter 34 or receiverdiameters. Therefore, in one embodiment, the wireless transmitter 34 isconfigured to operate to generate the oscillating electromagnetic field36 only when the portable electronic device 42 or the associatedwireless receiver is within a predetermined distance, e.g. about 1-10times the transmitter 34 or receiver diameters, from the wirelesstransmitter 34. Such activation may be based on signals or data from aproximity sensor or other device included in the circuit layer 12 orelsewhere that can sense the proximity of the portable electronic device42 with respect to the functional vehicle component 2. Alternatively,activation of the wireless transmitter 34 may be based on communication(e.g. blue tooth, cellular, near-field, RFID, Wi-Fi, or infraredcommunication) between the portable electronic device 42 and thefunctional vehicle component 2.

As depicted in FIG. 2, the smart functional wireless charger 82 mayinclude a light source 30 comprising a plurality of individual lightemitter elements 32 that are arranged, for example, in a ring around thewireless transmitter 34. In this ring or any other configuration, theindividual light emitter elements 32 each emit light that collectivelyindicates a location of the wireless transmitter 34 on the functionalvehicle component 2. Such indication is useful, since the pigmentedcoating 16 may optionally conceal the wireless transmitter 34 and otherportions of the circuit 20 from being visible through the pigmentedcoating 16, and a user therefore may not be able to locate the wirelesstransmitter 34 for charging the portable electronic device 42. However,light emitted by the light emitter elements 32 can be seen through thepigmented coating 16, and therefore the emitted light may provide anindication of the location of the wireless transmitter 34 to allow forwireless charging of the portable electronic device 42. In one aspect,the color of light emitted by the light emitter elements 32 changes froman initial color (for example, red light) present at the onset ofcharging the portable electronic device 42, to a second color (forexample, green light) when the portable electronic device 42 is fullycharged. Other lighting capabilities are contemplated for thisembodiment, for example, the light source 30 may be activated to emitlight when a door of the vehicle is opened, when the vehicle is started,and/or when a portable electronic device 42 is moved within apredetermined distance from the wireless transmitter 34. With respect tothe color of light emitted by the light source 30, different colors maybe provided based on the selection of light emitter elements 32 for usein the light source 30, based on the use of different lighting circuits,and/or based on programming of the microcontroller 46 to controlfunctioning of the light source 30 as desired. The functional layeredassembly 4 depicted in FIG. 2 may be included on any vehicle component 8as desired, for example on any interior surface of a vehicle such as avehicle seat, dashboard, or center console.

As described herein, one or more sensors 38 may be included in anelectronic circuit 20 of the circuit layer 12. The sensors 38 are notparticularly limited, and can include a sensor having any configurationincluding those that can sense pressure, temperature, proximity,location, speed, velocity, acceleration, tilt, motion, humidity, light,biometrics of a vehicle occupant, etc. In one embodiment, the circuitlayer 12 includes one or more pressure sensors. The pressure sensor mayinclude a first flexible layer of conductive material, a second flexiblelayer of dielectric material, and a third flexible layer of conductivematerial, where the second dielectric layer is arranged between andseparates the first and third conductive layers. The first and thirdconductive layers of the pressure sensor may optionally be formed byapplying a conductive ink as described herein, while the seconddielectric layer may be formed by applying a dielectric material, forexample an ink that is similar to the conductive ink as describedherein, but one that has dielectric properties.

As described herein, a switch 40 may be included in an electroniccircuit 20 of the circuit layer 12. The switch 40 may be operable tomake or break a conductive path in the circuit 20. The switch 40 may bea parallel plate capacitive switch for example, or other type of switchas desired such as a membrane switch, or a piezoelectric switch. Aparallel plate capacitive switch or piezoelectric switch may be arrangedsimilar to the pressure sensor as previously described herein, whereinthe capacitive switch or piezoelectric switch may include a first orbottom flexible layer of conductive material (e.g. ink) printed inelectrical communication with first conductive trace, followed by asequentially printed second middle layer arranged over the bottomconductive layer, and finally a third top flexible layer of conductivematerial printed over the middle layer and in electrical communicationwith a second conductive trace. For the capacitive switch, the middlelayer may include a flexible printed layer of dielectric material (e.g.a dielectric ink). For the piezoelectric switch, the middle layer mayinclude a piezoelectric material, which may or may not be printed andcured. The piezoelectric switch may include other layers and components.

The bottom layer of the switch is cured before applying the middlelayer, and if printed, the middle layer is cured before printing the toplayer. That is, the bottom, middle, and top layers of the switch 40 haveoverlapping areas, and the second middle layer is arranged between andthus separates the first and third conductive layers.

The dielectric middle layer in the dielectric switch may include one ormore sub-layers (e.g. two sub-layers) of the same or differentdielectric material printed and cured over the bottom layer. Thepiezoelectric middle layer in the piezoelectric switch may include oneor more sub-layers (e.g. two or more sublayers) of piezoelectricmaterial, which also may be sequentially printed and cured over thebottom layer. The conductive top and bottom layers may each include oneor more sub-layers (e.g. two sub-layers) of the same or differentconductive ink printed and cured below and above the middle layer.Thickness of the first, second, and third layers is not particularlylimited, and in one non-limiting example of the dielectric switch, thethickness may range from about 100 nm to 10 μm. The first and thirdconductive layers of the switch may optionally be formed by printing aconductive ink as described herein with respect to the flexible circuits20, while the second dielectric layer of the dielectric switch may beformed by printing a similar, but dielectric ink. In this configuration,the capacitive switch may be used as a pressure sensor when electricalcontact is made between the first and third conductive layers bypressing the first and third conductive layers together. Further, thecapacitive switch may be used to measure biometric characteristics of avehicle occupant in contact with the functional vehicle component 2,wherein for example, a rate at which electrical contact is made betweenthe first and third conductive layers may be used to determine aheartrate of the occupant.

The piezoelectric switch is not particularly limited, and thepiezoelectric material in the middle layer may include crystalpiezoelectric material, ceramic piezoelectric material, polymerpiezoelectric material, Group III-V and II-VI semiconductors, organicnanostructures, natural materials, bone, and combinations thereof. Thepiezoelectric material may include for example, lead zirconate titanate,barium titanate, quartz, berlinite, sucrose, Rochelle salt, topaz,tourmaline-group minerals, lead titanate, potassium niobate, sodiumtungstate, zinc oxide (wurtzite structure), Ba₂NaNb₅O₅, Pb₂KNb₅O₁₅,sodium potassium niobate, bismuth ferrite, sodium niobate, bariumtitanate, bismuth titanate, sodium bismuth titanate, polyvinylidenefluoride, vinylidene fluoride-trifluoroethylene-chlorotrifluoroethyleneterpolymer, P(VDF-TrFE-CTFE), vinylidenefluoride-trifluoroethylene-chlorofluoroethylene terpolymer,P(VDF-TrFE-CFE), or combinations thereof.

In one embodiment, the piezoelectric layer of the piezoelectric switchincludes a piezoelectric polymer, e.g. P(VDF-TrFE-CTFE) orP(VDF-TrFE-CFE), and is printed an cured between the bottom layer andthe top layer of the switch 40. The piezoelectric switch is actuatableto make or break a conductive path in the conductive trace 22 of thecircuit 20. The piezoelectric switch may be actuatable to make or breakthe conductive path by a user/occupant pressing the piezoelectricswitch, thereby deforming/compressing the piezoelectric layer betweenthe bottom and top layer of the switch 40, and thus causing thepiezoelectric material to generate a charge. Such charge may be sent toa flip-flop device in the switch 40, which is turned to steady “on”state, thus allowing current to pass therethrough and making theconductive path in the circuit 20. A further deformation/compression ofthe piezoelectric material will create an additional charge, which willcause the flip-flop device in the switch 40 to turn to a steady “off”stated, thus not allowing current to pass therethrough and breaking theconductive path in the circuit 20. Alternatively, the generated currentfrom the piezoelectric switch may utilize a semiconductor device such asa field effect transistor (FET), which provides a temporary “on” state,but reverts back to a steady “off” state when the charge dissipates.

The piezoelectric switch may be connected to a power source 44 of thevehicle, which can provide an electric charge to the piezoelectricswitch when the piezoelectric switch is actuated by a user pressing theswitch 40. The electric charge provided to the piezoelectric switch cancause deformations of the piezoelectric layer. Such deformations may behaptically sensed by a user when the user presses the switch 40 toactuate it. Such deformations may be felt as haptic vibrations havingvarious frequencies and/or amplitudes. Such vibrations may becharacterized as haptic signals that provide haptic feedback to the userthat the piezoelectric switch has been actuated to make or break theconductive path in the circuit 20.

The functional layered assembly 4 can include various other layers orcomponents as desired. In one embodiment and although not shown in thefigures, the functional layered assembly 4 includes a dielectric layerover or between one or more circuits 20 or conductive traces 22 of thecircuit layer 12. The dielectric material may generally include anon-conductive resin cured to form a dielectric layer. In oneembodiment, a dielectric layer is arranged between the circuit layer 12and the pigmented coating 16 in order to avoid moisture exposure duringformation of the pigmented coating 16, or to make the circuit layer 12more durable and resistant to abrasion and therefore maintain electricalconductivity after repeated use. A dielectric layer or coating may alsobe used as an insulator, for example, to provide electrical insulationbetween a first trace or circuit and an overlying second trace orcircuit. The dielectric layer may cover only the trace or circuit, ormay also generally cover other portions of the circuit layer 12 orleather sheet 10. That is, the dielectric layer may be generally appliedover the first circuit as one continuous layer wherein the conductivetraces of the first circuit and spaces therebetween are covered by thedielectric layer, or may be applied as a discontinuous layer that coversonly the conductive traces of the first circuit, but not the spacestherebetween. In one non-limiting example, the dielectric layer isapplied only at a location where a second trace or circuit overlaps thefirst trace or circuit. In this regard, the circuit layer 12 may includea plurality of separate and distinct traces 22 and/or circuits 20 thatmay be arranged in different planes or sub-layers of the circuit layer12, wherein various conductive traces 22 may overlap each other. Forexample, with reference to FIGS. 1 and 2, although the traces 22 aredepicted as not overlapping (and appear to be in the same plane orsub-layer), the traces 22 may be in different planes within the circuitlayer 12 and be configured to overlap each other. As such, the circuitlayer 12 may include a first trace printed on the leather sheet 10,followed by a dielectric layer applied over the first trace, and then asecond trace printed on the leather sheet 10 and at least partiallyoverlapping the first trace, yet because of the intermediary dielectriclayer, the first and second trace are electrically isolated form oneanother. As such, the present subject matter is not limited to anyparticular shape or orientation of the traces 22, circuits 20 andelectronic elements 24 as depicted in the various figures, and insteadcan have other arrangements and orientations. In another example, aconductive ink is first printed directly on the leather sheet 10 inorder to form a wireless transmitter 34, a dielectric layer is thenarranged over the wireless transmitter 34, then a conductive ink isprinted over the dielectric layer (or overlaps a portion of it) in orderto form a separate conductive trace for a different electronic element24 (such as for a light emitter element 32), and then optionally anotherdielectric layer is printed over the light emitter trace to provideabrasion resistance for the underlying layers. In this example, thedielectric layer between the wireless transmitter 34 and the lightemitter trace electrically isolate the wireless transmitter 34 from thelight emitter trace.

In another embodiment, the functional layered assembly 4 includes amicrocontroller 46 electrically connected to the circuit layer 12 at anedge of the leather sheet 10. The microcontroller 46 may be used toelectrically connect to the circuits 20 of the circuit layer 12, andthus may provide communication to and from the one or more circuits 20and electronic elements 24, or to control functions of the one or morecircuits 20 and electronic elements 24. The microcontroller 46 may bemounted at the edge of the leather sheet 10 and functional layeredassembly 4 before or after the functional layered assembly 4 is fixedover the surface 6 of the vehicle component 8. The various vehicleelectronic systems, such as an ECU 26 or HMI 28, may be electricallyconnected to functional layered assembly 4 through the microcontroller46 in order to communicate with the functional layered assembly 4.

The one or more circuits 20 and the electronic elements 24 may each beelectrically connected to a power source 44 of the vehicle for providingelectrical power to the circuits 20 for activating the electronicelements 24. The vehicle power source 44 may comprise a vehicle battery,engine, or alternator, for example. The power source 44 may be connectedto the functional layered assembly 4 through the microcontroller 46. Inone embodiment, a smart functional vehicle system 84 includes a smartfunctional vehicle component 2, along with one or more of themicrocontroller 46, ECU 26, HMI 28, and vehicle power source 44.

With reference to FIG. 3, an illustrative example of a smart functionalvehicle component 2 includes a smart functional vehicle seat 48 (alsoreferred to herein as “vehicle seat” or “seat”). The seat 48 includes abottom 50, a back 52, and a headrest 54. The vehicle seat 48 includes afunctional layered assembly 4 over the front surface 56 of the back 52of the seat 48. It will be appreciated that although visibility of thecircuit 20 in the functional layered assembly 4 may be inhibited orprevented by pigmented coating 16, the circuit 20 is schematicallydepicted in FIG. 3 in order to indicate it's arrangement on the vehicleseat 48. As in other embodiments, the functional layered assembly 4 ofthe vehicle seat 48 may include one or more electronic elements 24. Asdepicted, the functional layered assembly 4 of the seat 48 includes alight source 30 including two individual light emitter elements 32, andtwo sensors 38. More or less, and different electronic elements 24 maybe included as desired on the seat 48. The sensors 38 may be configuredto sense biometrics, such as heart rate, body temperature, bloodpressure, etc., of a vehicle occupant who is sitting on the seat 48. Thelight source 30 may be configured to activate when a vehicle door isopen to provide illumination to the seat 48, or during operation of thevehicle in order to provide mood lighting in a passenger compartment ofthe vehicle. Further, a switch 40, for example a piezoelectric switch,may be provided to manually turn the light source 30 on or off or toproduce other functions. More or less, and different electrical elements24 may be included on the seat 48, and at different locations on theseat 48, including on the bottom 50, the headrest 54, or an armrest (notshown).

With reference to FIG. 4, an illustrative example of a smart functionalvehicle component 2 includes a smart functional steering wheel 58 (alsoreferred to herein as “steering wheel”). The steering wheel 58 includesa central hub 60, an outer wheel 62, and spokes 64 extending between thehub 60 and wheel 62. A functional layered assembly 4 may be includedover one or more of the hub 60, wheel 62 and spokes 64. In oneembodiment, the wheel 62 includes one or more sensors 38. The one ormore sensors 38 may be pressure sensors for sensing the presence of auser's hand on the wheel 62. The sensors 38 may also be configured tosense biometrics, such as heart rate, body temperature, blood pressure,etc., of a user. It will be appreciated that although visibility of thesensors 38 may be inhibited or prevented by pigmented coating 16 of thefunctional layered assembly 4, a plurality of sensors 38 areschematically depicted in FIG. 4 in order to indicate their arrangementon the wheel 62. As depicted, the sensors 38 are spaced from one anotherand are arranged on the exposed portions of the wheel 62 and around theentire circumference of the wheel 62. In a non-limiting example, each ofthe sensors 38 is circumferentially spaced by no more than two inchesfrom an adjacent sensor 38. In other words, there is no portion of morethan two consecutive inches along the entire circumference of the wheel62 that is without a sensor 38. By this arrangement, anywhere a driverplaces his/her hands on the wheel 62, there will be a sensor 38 there sothat the sensors 38 can collectively sense the presence of a user's handno matter where the user's hand contacts the wheel 62. The wheel 2 mayalternately include one continuous sensor arranged on the exposedportions of the wheel 62 and extending around the entire circumferenceof the wheel 62.

In another embodiment, the hub 60 includes a light source 30 comprisingan array 68 of individual light emitter elements. The light emitterelements, which are not individually depicted in FIG. 4, may be arrangedin the array 68 in such a way that light emitted from the array 68conveys information to a vehicle occupant. As depicted, the array 68 isdisplaying a visual indicator 70, which may be a directional indicatorthat is based on information or data derived from a navigation system.The visual indicator 70 is indicating a direction (i.e. right turn) forthe vehicle to follow in order to reach a predetermined destination.

As shown, the array 68 covers an area on the surface of the hub 60 andhas an illuminated area 72 and a non-illuminated area 74. The right turnvisual indicator 70 is presented by a contrast between the illuminatedarea 72 of the array 68 (light from which is visible through thepigmented coating 16 of the functional layered assembly 4) and thenon-illuminated area 74 of the array 68 (which is not visible throughthe pigmented coating 16). As such, the visual indicator is determinedby activation of a specific combination of individual light emitterelements in the array 68. As will be appreciated, a differentcombination of individual light emitter elements in the array 68 may beactivated as desired in order to provide a different arrangement betweenthe illuminated area 72 and the non-illuminated area 74, such that lightemitted by the illuminated area 72 may convey other visual indicatorsand other information, such as other directional indicators, a currentspeed or time, etc.

In another embodiment, one or more of the spokes 64 of the steeringwheel 58 may each include a switch 40, such as a capacitive switch orpiezoelectric switch. As schematically depicted, one switch 40 isincluded on each of two of the spokes 64. It will be appreciated thatalthough visibility of the switches 40 may be inhibited or prevented bythe pigmented coating 16 of the functional layered assembly 4, theswitches 40 are schematically depicted in FIG. 4 in order to indicatetheir arrangement on the spokes 64. The switches 40 may be configured tocontrol one or more functions of the vehicle or vehicle systems, e.g. anentertainment system.

As depicted, a light source 30 comprising a plurality of individuallight emitter elements 32, are provided on the spokes 64 and arearranged around the perimeter of the two switches 40. In thisconfiguration, the individual light emitter elements 32 each emit lightthat collectively indicates a location of the switches 40. Suchindication is useful, since the pigmented coating 16 may conceal theswitches 40 from being readily visible through the pigmented coating 16,and a user may not be able to locate the switches 40 for controlling oneor more functions of the vehicle or vehicle systems. However, lightemitted by the light emitter elements 32 can be seen through thepigmented coating 16, and therefore the emitted light provides anindication of the location of the switches 40. In a non-limitingexample, the light emitter elements 32 may be activated to continuouslyemit light during operation of the vehicle in order to indicate thelocation of the switches 40, and may be deactivated when the vehicle isnot being operated to thereby present a plain top surface for the spokes64 of the steering wheel 58. More or less, and different electronicelements 24 may be included as desired on the steering wheel 58.

With reference to FIG. 5, an illustrative example of a smart functionalvehicle component 2 includes a smart functional dashboard 76 (alsoreferred to herein as “dashboard”), which may include an instrumentpanel 78 and a glove box 80. The dashboard 76 includes a functionallayered assembly 4 as discussed herein. The functional layered assembly4 is fixed over a surface of the dashboard 76 and presents as a plaintop surface for the dashboard 76. As depicted, the dashboard 76 includesa light source 30 comprising an array 68 of individual light emitterelements. The array 68 depicted in FIG. 5 may be similar to the array 68depicted in FIG. 4 on the hub 60 of the steering wheel 58.

As depicted, the array 68 is displaying a visual indicator 70, which maybe a current speed of the vehicle. As in FIG. 4, the array 68 covers anarea on the surface of the dashboard 76 and has an illuminated area 72and a non-illuminated area 74. The visual indicator 70 showing thecurrent speed is presented by a contrast between the illuminated area 72of the array 68 and the non-illuminated area 74 of the array 68. Assuch, the visual indicator 70 is determined by activation of a specificcombination of individual light emitter elements in the array 68. Aswill be appreciated, a different combination of individual light emitterelements in the array 68 may be activated as desired in order to providea different arrangement between the illuminated area 72 and thenon-illuminated area 74, such that light emitted by the illuminated area72 may convey other visual indicators and other information, such as acurrent time, the current amount of fuel reserves for the vehicle, etc.Activation of the array 68 on the dashboard 76 or on the steering wheel58 may be activated by audible signals from a user. For example, a usermay audibly request that the array 68 on the dashboard 76 or on thesteering wheel 58 display the current speed, current amount of fuelreserves for the vehicle, distance from a selected destination, etc.More or less, and different electronic elements 24 may be included asdesired on the dashboard 76.

With reference to FIG. 6, an illustrative example of a smart functionalvehicle component 2 includes a smart functional door panel 86 (alsoreferred to herein as “door panel”). The door panel 86 includes afunctional layered assembly 4 as discussed herein. The functionallayered assembly 4 is fixed over a surface of the door panel 86 andpresents as a plain top surface for the door panel 86. As depicted, thedoor panel 86 includes. The door panel 86 may include one or moreswitches 40, such as a capacitive or piezoelectric switch, that areoperable to move a window 88, adjust a mirror 90, or operate an interiorlight 92 of the vehicle. The smart functional door panel 86 may includea light source 30 comprising a plurality of individual light emitterelements 32 that are arranged on the circuit 20 and, for example, in aring around the switches 40. In this ring configuration, the individuallight emitter elements 32 each emit light that collectively indicates alocation of the switches 40 on the functional door panel 86. Suchindication is useful, since the pigmented coating 16 may conceal theswitches 40 and other portions of the circuit 20 from being visiblethrough the pigmented coating 16, and a user therefore may not be ableto readily locate the switches 40 for operating the window 88 andmirrors 90. However, light emitted by the light emitter elements 32 canbe seen through the pigmented coating 16, and therefore the emittedlight may provide an indication of the location of the switches 40 toallow for operation of the switches 40. Further, if the switches 40 arepiezoelectric switches, their operation may result in haptic feedbackbeing provide to a user to indicate that the switches 40 have beenoperated.

The smart functional vehicle component 2 may provide variousfunctionalities in a vehicle including a dynamic illumination experienceby providing changing the color of emitted light to the interior of thevehicle according to a vehicle speed, a driving mode, a driver'smood/condition based on biofeedback data, a current music selection. Thesmart functional vehicle component 2 may also be used to monitor adriver's condition to maintain safe driving using sensors 38 to monitorheart rate, peripheral capillary oxygen saturation, or a driver's healthcondition, and the data from such monitoring can be used to improve adriver's user experience. Illumination provided by the functionalvehicle component 2 can also be utilized to keep a driver attentive byprovide real time feedback. When the functional vehicle component 2 is aseat 48, the use of a functional vehicle component 2 can reduce thecomplexity of the seat because the functional vehicle component 2 caninclude a number or different electrical elements 24. That is, thefunctional vehicle component 2 can be utilized as a pressure sensor onthe seat, and measure pressure points. This can help to identify driverseat pressure and automatically adjust seat position for driver comfort.This also reduces the need for a separate component of a pressure sensorinstalled separately on a seat. The functional vehicle component 2 canalso be used to give opportunities to create innovative vehicle styling,such as creating navigation directional indicators (FIG. 4) on asteering wheel 58, or a vehicle speed displayed on an interior panel(FIG. 5). The functional vehicle component 2 can also be utilized as awireless charging pad (FIG. 2) for charging a portable electronic device42.

The present subject matter includes a method of producing a functionallayered assembly 4. The functional layered assembly 4 may be produced bypassing a hide through conventional processes such as soaking, sammying,shaving, fleshing/splitting, drying, staking, and milling. Then, afterapplication of a base coat, the hide is set aside to rest. The hide isthen cut to a predetermined shape to produce a leather sheet 10 thatwill fit over a particular vehicle component 8. An electronic circuit 20is then printed, utilizing conductive ink, on the A-surface 14 of theleather sheet 10. The conductive ink can be applied through any method,and in an illustrative embodiment, is applied by one of (a) screenprinting, (b) aerosol jet printing (c) inkjet printing. A light source30 (e.g. micro LED's), or other electronic element 24, may be formedwith or placed on the circuit 20. Then pigmented coating 16 can beapplied over the circuit 20 and light source 30 to thereby produce afunctional layered assembly 4. The functional layered assembly 4 can beplaced in interior of a vehicle as an interior panel lining, doorlining, or seat cover for example.

The present subject matter includes a method of producing a functionalvehicle component 2. The functional vehicle component 2 may be, forexample, a smart functional wireless charger 82, a smart functionalvehicle seat 48, a smart functional steering wheel 58, a smartfunctional dashboard 76, or other smart functional vehicle component.

The functional vehicle component 2 may be produced by fixing a leathersheet 10 over a surface of a vehicle component 8, such that the leathersheet 10 is conformed to contours of the vehicle component 8. A flexibleelectronic circuit 20 is applied (e.g. printed) to an A-surface 14 ofthe leather sheet 10, and a pigmented coating 16 is arranged over thecircuit 20. Visibility of the circuit 20 through the pigmented coating16 is optionally concealed by the pigmented coating, and in oneembodiment the circuit 120 is not visible through the pigmented coating16. In an embodiment, the pigmented coating 16 is a pigmented layer, anda pigment loading in the pigmented coating 16 may be sufficient toinhibit or prevent the circuit 20 from being visible through thepigmented coating 16. The circuit 20 and the pigmented coating 16 may beapplied to the leather sheet 10 before or after the leather sheet 10 isfixed over the surface 6 of the vehicle component 8. During fixing ofthe leather sheet 10 over the surface 6 of the vehicle component 8, thecircuit 20 is conformed to contours of the surface 6 of the vehiclecomponent 8. The method may further include applying a dielectric layerover the circuit 20, wherein the dielectric layer is arranged betweenthe circuit 20 and the pigmented coating 16.

The method may include electrically connecting the circuit 20 to avehicle ECU 26, to a vehicle power source 44, a vehicle HMI 28, or othervehicle systems, and such connections may be made directly by a wire, orthrough an intermediary microcontroller 46 located at an edge of theleather sheet 10.

The method may include providing a light source 30 that emits light whenactivated, and electrically connecting the light source to the circuit20. The light source 30 may comprise one or more individual lightemitter elements 32, such as a micro LED, which may be connected to thecircuit 20 for example by soldering of electrical contacts or othermethod. The light source 30 is arranged within the flexible circuitlayer 12 and directly in contact with the circuit 20. As such, thepigmented coating 16 is arranged over the circuit 20 and over the lightsource 30. Visibility of the light source 30 through the pigmentedcoating 16 may be inhibited, by the pigmented coating 16, and in oneembodiment the light source 30 is not visible through the pigmentedcoating 16, but light emitted by the light source 30 is visible throughthe pigmented coating 16. The light source 30 is arranged in such a way,or is configured to emit light in such a way that light emitted by thelight source provides visual indicators that convey information to avehicle occupant.

The method may include applying an acrylic urethane anti-soilingcomponent over the A-surface of the leather sheet 10, wherein theanti-soiling component is included a) as part of the pigmented coating16, or b) as a topcoat (i.e. an anti-soiling component layer 18) overthe pigmented coating 16.

In an embodiment, the vehicle component 8 is a steering wheel 58, thecircuit 20 includes pressure sensors 38, and the pressure sensors 38 arearranged around the entire circumference of the steering wheel 58.

In another embodiment, the vehicle component 8 is a seat 48, the circuit20 includes a biometric sensor 38, which is configured to measurebiometrics of a user sitting on the seat 48.

The method may include applying a second flexible electronic circuit tothe A-surface 14 of the leather sheet 10. The second flexible electroniccircuit may be similar to the first flexible electronic circuit, suchthat the pigmented coating 16 is arranged over the second circuit. Assuch, the pigmented coating 16 may inhibit or prevent the second circuitfrom being visible through the pigmented coating 16. The second circuitis configured to perform a different function than the first circuit,which may mean that each circuit is electrically isolated/separated fromthe other circuit, or that each circuit can be independently operated,or that each circuit can function separately from the other circuits. Inone embodiment, the second circuit is electrically isolated from thefirst circuit.

In an embodiment, the second circuit includes a wireless transmitter 34,which is configured to generate an oscillating electromagnetic field 36when an associated portable electronic device 42 is within apredetermined distance from the wireless transmitter 34. The lightsource 30 may be configured to emit light that indicates a location ofthe wireless transmitter 34 when the portable electronic device 42 iswithin a predetermined distance from the wireless transmitter 34.

In another embodiment, the second circuit may include a switch 40, suchas a capacitive or piezoelectric switch, that is operable to make orbreak a conductive path 22 in the second circuit; and the light source30 is configured to emit light that indicates a location of the switch40.

The present subject matter also includes a method of producing a vehiclesystem 84. The method includes applying a flexible electronic circuit 20to an A-surface 14 of a leather sheet 10. A light source 30 iselectrically connected to the circuit 20. The light source 30 isconfigured to emit light when supplied with electrical power. Apigmented coating 16 is arranged over the circuit 20 and over the lightsource 30. The method includes fixing the leather sheet 10 over asurface 6 of a vehicle component 8 such that the A-surface 14 of theleather sheet 10 is facing away from the vehicle component 8. Thecircuit 20 is electrically connected to a vehicle electronic controlunit 26 and a vehicle power source 44. The pigmented coating 16optionally inhibits or prevent the circuit 20 and the light source 30from being visible through the pigmented coating 16. However, lightemitted by the light source 30 is visible through the pigmented coating16. In one embodiment, the vehicle component 8 comprises an interiorpanel, a door, a seat, a steering wheel, a dashboard, a center console,or a gear shifter.

A method of producing a functional leather component may includeproviding a leather sheet 10; applying to an A-surface 14 of the leathersheet 10, a flexible electronic circuit 12 including a piezoelectricswitch 40 that can be actuated to make or break a conductive path 22 inthe circuit 12; and arranging a pigmented coating 16 over the circuit12. When a user actuates the switch 40 to make or break the conductivepath 22 in the circuit 12, the piezoelectric switch 40 provides hapticfeedback to the user that the piezoelectric switch 40 has been actuated.The pigmented coating 16 may inhibit or prevent the circuit 12 includingthe piezoelectric switch 40 from being visible through the pigmentedcoating 16. The piezoelectric switch 40 may be applied to the A-surface14 of the leather sheet 10 by printing a piezoelectric material on theA-surface 14 of the leather sheet 10. The leather sheet 10, the flexibleelectronic circuit 12, and the pigmented coating 16 may then be embossedto impart an embossed pattern over the A-surface 14 of the leather sheet10. Embossing may include passing the leather sheet 14, the flexibleelectronic circuit 12, and the pigmented coating 16 through aroll-to-roll embosser. A light source 30 may be provided that emitslight when electrical power is supplied to the light source 30. Thelight source 30 may be electrically connected to the circuit 12. Thepigmented coating 16 may be arranged over the light source 30, and mayinhibit or prevent the light source 30 from being visible through thepigmented coating 16. However, light emitted by the light source 30 maybe visible through the pigmented coating 16. The light source 30 mayinclude a micro light emitting diode and may be configured to emit lightthat indicates a location of the piezoelectric switch 40. An acrylicurethane anti-soiling component may be applied over the A-surface 14 ofthe leather sheet 10. The anti-soiling component may be included a) aspart of the pigmented coating 16, or b) as a top coat 18 over thepigmented coating 16. The leather sheet 10 may be fixed over a surface 6of a vehicle component 8. During fixing, the circuit 12 may conform tocontours of the surface 6 of the vehicle component 8. The vehiclecomponent 8 may include a steering wheel, a seat, an arm rest, a centerconsole, a dashboard, an interior panel, a door, a gear shifter, orcombinations thereof.

A method of producing a functional vehicle component 2 may includeapplying to the A-surface 14 of the leather sheet 10, a flexibleelectronic circuit 12 including a piezoelectric switch 40 that isactuatable to make or break a conductive path 22 in the circuit 12;arranging the pigmented coating 16 over the A-surface 14 of the leathersheet 10 and over the flexible electronic circuit 12 including thepiezoelectric switch 40; fixing the leather sheet 10 over the surface 6of the vehicle component 8 such that the A-surface 14 of the leathersheet 10 is facing away from the vehicle component 8; and connecting thecircuit 12 to a vehicle electronic control unit 26 and a vehicle powersource 44. Upon actuation of the piezoelectric switch 40 to make orbreak the conductive path 22 in the circuit 12, the piezoelectric switch40 may provide a haptic signal that indicates the actuation of thepiezoelectric switch 40. The pigmented coating 16 may inhibit or preventthe circuit 12 including the piezoelectric switch 40 from being visiblethrough the pigmented coating 16. The vehicle component may include asteering wheel, a seat, an arm rest, a center console, a dash board,interior panel, a door, a gear shifter, or combinations thereof.

It will be appreciated that various of the above-disclosed and otherfeatures and functions, or alternatives or varieties thereof, may bedesirably combined into many other different systems or applications.Also that various presently unforeseen or unanticipated alternatives,modifications, variations or improvements therein may be subsequentlymade by those skilled in the art which are also intended to beencompassed by the following claims.

The invention claimed is:
 1. A method of producing a functional leather component, comprising: providing a leather sheet; applying to a first side of the leather sheet, a flexible electronic circuit including a piezoelectric switch that can be actuated to make or break a conductive path in the circuit; and arranging a pigmented coating over the circuit; wherein the pigmented coating comprises pigment dispersed in a cured polymer film; wherein when the switch is actuated to make or break the conductive path in the circuit, the piezoelectric switch provides haptic feedback that the piezoelectric switch has been actuated.
 2. The method according to claim 1, wherein the piezoelectric switch is applied to the first side of the leather sheet by printing a piezoelectric material on the first side of the leather sheet.
 3. The method according to claim 1, further comprising embossing the leather sheet and the flexible electronic circuit to impart an embossed pattern over the first side of the leather sheet.
 4. The method according to claim 3, wherein embossing includes passing the leather sheet and the flexible electronic circuit through a roll-to-roll embosser.
 5. The method according to claim 1, wherein: the pigmented coating has a pigment loading sufficient to camouflage the circuit; and the first side is the grain side of the leather sheet.
 6. The method according to claim 5, further comprising: providing a light source that emits light when electrical power is supplied to the light source, and electrically connecting the light source to the circuit, wherein the pigmented coating is arranged over the light source, wherein light emitted by the light source is visible through the pigmented coating, wherein the light source comprises a micro light emitting diode, and wherein the light source is configured to emit light that indicates a location of the piezoelectric switch.
 7. The method according to claim 5, further comprising applying an acrylic urethane anti-soiling component over the first side of the leather sheet, wherein the anti-soiling component is included a) as part of the pigmented coating, or b) as a top coat over the pigmented coating.
 8. The method according to claim 1, further comprising fixing the leather sheet over a surface of a vehicle component, wherein during fixing, the circuit conforms to contours of the surface of the vehicle component.
 9. The method according to claim 8, wherein the vehicle component is selected from the group consisting of a steering wheel, a seat, an arm rest, a center console, a dashboard, an interior panel, a door, a gear shifter, and combinations thereof.
 10. A functional vehicle component comprising a vehicle component covered by a functional leather assembly, wherein: the functional leather assembly includes: a leather sheet covering the vehicle component; and a flexible electronic circuit arranged on an outermost surface of the leather sheet that faces away from the vehicle component, the flexible electronic circuit including a piezoelectric switch that can be actuated to make or break a conductive path in the circuit; and upon actuation of the piezoelectric switch to make or break the conductive path in the circuit, the piezoelectric switch provides a haptic signal that indicates the actuation of the piezoelectric switch.
 11. The functional vehicle component according to claim 10, wherein the piezoelectric switch includes a printed piezoelectric material arranged between two conductive layers.
 12. The functional vehicle component according to claim 10, wherein the functional leather assembly includes an embossed pattern over the outermost surface of the leather sheet and over the flexible electronic circuit.
 13. The functional vehicle component according to claim 10, wherein the circuit further includes a light source.
 14. The functional vehicle component according to claim 13, wherein: the light source comprises a micro light emitting diode; and the light emitted by the light source indicates a location of the piezoelectric switch.
 15. The functional vehicle component according to claim 10, further comprising a pigmented coating arranged over the circuit, including the piezoelectric switch.
 16. The functional vehicle component according to claim 15, wherein the functional leather assembly further includes an acrylic urethane anti-soiling component over the outermost surface of the leather sheet, wherein the anti-soiling component is included a) as part of the pigmented coating, or b) as a top coat over the pigmented coating.
 17. The functional vehicle component according to claim 10, wherein: the functional leather assembly is fixed over a surface of the vehicle component, and the circuit conforms to contours of the surface of the vehicle component.
 18. The functional vehicle component according to claim 10, wherein the vehicle component is selected from the group consisting of a steering wheel, a seat, an arm rest, a center console, a dashboard, an interior panel, a door, a gear shifter, and combinations thereof.
 19. A method of producing a functional vehicle component, comprising: applying to a first surface of a leather sheet, a flexible electronic circuit including a piezoelectric switch that is actuatable to make or break a conductive path in the circuit; fixing the leather sheet over a surface of a vehicle component such that the first surface of the leather sheet is facing away from the vehicle component to thereby define an outermost surface of the leather sheet; and connecting the circuit to a vehicle electronic control unit and a vehicle power source; wherein upon actuation of the piezoelectric switch to make or break the conductive path in the circuit, the piezoelectric switch provides a haptic signal that indicates the actuation of the piezoelectric switch.
 20. The method according to claim 19, wherein: the method further comprises arranging a pigmented coating over the first surface of the leather sheet and over the flexible electronic circuit including the piezoelectric switch; and the vehicle component is selected from the group consisting of a steering wheel, a seat, an arm rest, a center console, a dash board, interior panel, a door, a gear shifter, and combinations thereof. 